JP2018202771A - Fiber laminated sheet member and method for producing fiber molded article using the fiber laminated sheet member - Google Patents

Abstract

To provide a fiber laminated sheet member excellent in designability and productivity, and a method for producing a fiber molded article using the fiber laminated sheet member.SOLUTION: A fiber laminated sheet member 10 is formed by: joining a skin film 14 that is seen through onto one surface of a fiber sheer 12 made of a carbon fiber knit; and joining a substrate film 16 constituting a base of a sheet member 10 onto the other surface, the sheet member 10 is set in a preliminary molding die 20 to preliminarily mold the fiber laminated sheet member, the preliminarily molded fiber laminated sheet member 10 is set in a molding die 22, and a thermoplastic resin 18 is injection-molded to the substrate film 16 side to obtain a fiber molded article. The strength of the molded article can be further improved by causing the thermoplastic resin 18 to contain a carbon fiber.SELECTED DRAWING: Figure 1

Description

  The present invention relates to a fiber laminated sheet member and a method for producing a fiber molded article using the fiber laminated sheet, and particularly to a lightweight and high strength carbon fiber sheet member and a fiber molded article producing method using the same.

  A carbon fiber molded product made of carbon fiber reinforced resin generally called CFRP (Carbon Fiber Reinforced Plastics) has attracted attention. Since this carbon fiber reinforced resin generally has both a small specific gravity and a large mechanical strength, the molded product is used, for example, as a substitute for a steel plate part of a vehicle. As such a carbon fiber molded product, for example, there is one described in Patent Document 1 below. This carbon fiber molded article is obtained by impregnating a carbon fiber sheet made of a carbon fiber woven fabric with a thermosetting resin to form a prepreg, and bonding a thermoplastic resin film on both sides to form a carbon fiber laminated sheet member. The sheet member is preformed into a prescribed shape by hot press molding, the preform is set in a mold, and a thermoplastic resin is injection-molded from the side opposite to the surface of the molded product. In this carbon fiber molded product, the eyes of the carbon fiber can be seen through a transparent thermoplastic resin or thermosetting resin, and the design is excellent.

JP 10-138354 A

  As represented by Patent Document 1, a carbon fiber sheet made of a carbon fiber fabric, a so-called fabric, is used for the carbon fiber molded article. However, carbon fiber fabrics generally lack flexibility or softness and are therefore difficult to mold. For this reason, when a carbon fiber laminated sheet member using a carbon fiber woven sheet is set in a mold, for example, warping and wrinkling are likely to occur, the productivity is low, and the design property is likely to deteriorate. On the other hand, a technique of injection-molding a carbon fiber-containing thermoplastic resin (CFRTP: Carbon Fiber Reinforced Thermo Plastics) is also widely used.

  The present invention has been made in view of the above problems, and an object of the present invention is to provide a fiber laminated sheet member excellent in design and productivity, and a method for producing a fiber molded article using the fiber laminated sheet member. There is to do.

In order to achieve the above object, the fiber laminated sheet member according to claim 1,
In the fiber laminated sheet member in which both surfaces of the fiber sheet are coated with a film, the fiber sheet is composed of a knitted fabric of reinforcing fibers, and at least one of the films coated on both surfaces of the fiber sheet is transparent, The film coated on both sides of the fiber sheet has a moldability.

  According to this configuration, a fiber sheet made of a knitted reinforcing fiber is excellent in flexibility and flexibility, and is easy to mold. For example, when a fiber laminated sheet member is set in a mold, Since the film coated on both sides of the fiber sheet has moldability, the productivity is excellent, and the eyes of the reinforcing fibers can be seen through the transparent film, so that the design is also excellent.

  The manufacturing method of the fiber molded article using the fiber lamination sheet member of Claim 2 sets the fiber lamination sheet member of Claim 1 in a metal mold | die, and is the film coat | covered on both surfaces of the said fiber sheet. If only one of them is transparent, the thermoplastic resin is injection-molded on the opposite side of the transparent film, or on both sides of the film that is transparent on either side of the fiber sheet. It is characterized by doing.

  According to this configuration, the thermoplastic resin layer that exhibits sufficient strength after curing is formed on the back side or the inside of the fiber laminated sheet member, so that the fiber molded product using the fiber laminated sheet member has a prescribed strength. Can be granted.

  The method for producing a fiber molded article using the fiber laminated sheet member according to claim 3 is the method for producing a fiber molded article using the fiber laminated sheet member according to claim 2, wherein the thermoplastic resin is injection molded. Before, the fiber laminated sheet member is preformed in a preforming mold.

  According to this configuration, the fiber laminated sheet member is formed in the surface shape or the outer shape of the fiber molded product before the thermoplastic resin is injection-molded by preforming the fiber laminated sheet member in the preforming mold. Therefore, the fiber molded article using the fiber laminated sheet member can be surely formed into a specified shape.

  The method for producing a fiber molded article using the fiber laminated sheet member according to claim 4 is the method for producing a fiber molded article using the fiber laminated sheet member according to claim 2 or 3, wherein the thermoplastic resin is provided in the thermoplastic resin. Reinforcing fibers are contained.

  According to this configuration, the thermoplastic resin containing the reinforcing fiber has a higher strength after curing than the thermoplastic resin containing no reinforcing fiber. Therefore, by adding the reinforcing fiber to the thermoplastic resin, a fiber molded product is obtained. It is possible to further improve the strength.

The fiber laminated sheet member according to claim 5,
In a fiber laminated sheet member in which one side of a fiber sheet is covered with a film and the other side is covered with a sheet, the fiber sheet is composed of a knitted fabric of reinforcing fibers and is covered on one side of the fiber sheet. The film is transparent and has moldability, and the sheet coated on the other surface of the fiber sheet is a thermoplastic resin sheet.

  According to this configuration, a fiber sheet made of a knitted fabric of reinforcing fibers is excellent in flexibility and flexibility, and is easy to mold. For example, when a fiber laminated sheet member is set in a thermoforming mold and subjected to hot press molding. It is not prone to warping and wrinkling, and the film has moldability and the sheet is a thermoplastic resin sheet, so it is excellent in productivity during hot press molding, and the eyes of the reinforcing fibers can be seen through the transparent film. Since it is visible, it is also excellent in design. Moreover, a strong molded product can be obtained only by hot press molding the fiber laminated sheet member.

  The fiber laminated sheet member according to claim 6 is the fiber laminated sheet member according to claim 5, characterized in that reinforcing fibers are contained in the thermoplastic resin sheet.

  According to this configuration, the thermoplastic resin containing the reinforcing fiber has a higher strength after curing than the thermoplastic resin not containing the fiber, so that the reinforcing fiber is contained in the thermoplastic resin sheet, so that the fiber The strength of the fiber molded product using the laminated sheet member can be further improved.

  The method for producing a fiber molded article using the fiber laminated sheet member according to claim 7 is characterized in that the fiber laminated sheet member according to claim 5 or 6 is set in a thermoforming mold and hot press molded. And

  According to this configuration, a strong fiber molded product can be obtained simply by hot press molding the fiber laminated sheet member.

  As described above, according to the present invention, a fiber sheet made of a knitted fabric of reinforcing fibers is excellent in flexibility and flexibility and easy to mold. For example, a fiber laminated sheet member is molded in a mold. When it is done, it is hard to produce wrinkles and wrinkles, and since the film and sheet covering the fiber sheet together have moldability, it is excellent in productivity, and because the eyes of the reinforcing fiber can be seen through the transparent film, it is designed Also excellent. In addition, since it is easy to form a fiber molded product, labor and time during molding can be reduced, and the cost can be reduced.

It is explanatory drawing which shows 1st Embodiment of the fiber lamination sheet member of this invention. It is explanatory drawing of the preforming in the manufacturing method of the fiber molded product using the fiber lamination sheet member of FIG. It is explanatory drawing of the manufacturing method of the fiber molded product using the preformed product of FIG. It is explanatory drawing which shows 2nd Embodiment of the fiber lamination sheet member of this invention. It is explanatory drawing of the manufacturing method of the fiber molded article using the fiber lamination sheet member of FIG.

  DESCRIPTION OF EMBODIMENTS Embodiments of a fiber laminated sheet member of the present invention and a method for producing a fiber molded product using the fiber laminated sheet member will be described in detail with reference to the drawings. Drawing 1 is an explanatory view of a lamination process in which a 1st embodiment of a fiber lamination sheet member of the present invention is shown. In this embodiment, films 14 and 16 are joined to both surfaces of a fiber sheet 12 made of a knitted fabric of reinforcing fibers to form a three-layer fiber laminated sheet member 10. In this embodiment, carbon fibers are used as the reinforcing fibers constituting the fiber sheet 12. Further, in this embodiment, the fiber sheet 12 and the films 14 and 16 are joined by roll forming. For specific joining, welding (fusion), pressure bonding, adhesion with an adhesive, or the like is selected according to the material of the fiber sheet 12 or the films 14 and 16 and the use of the molded product.

  The knitted fabric of carbon fibers constituting the fiber sheet 12 of this embodiment has various knitting methods (stitches) depending on the use of the fiber molded product using the fiber laminated sheet member 10 and the design required for the fiber molded product. ) Can be selected. Traditionally, it has been considered difficult to knit carbon fibers, but in recent years, not only knitting carbon fibers but also various knitting methods (knitting) are possible. Since the stitches of the carbon fiber knitted fabric are greatly involved in the design properties of the carbon fiber molded product, the stitch, that is, the knitting method, is selected according to the use of the fiber molded product and the design properties required of the fiber molded product. Carbon fiber stitches are determined by the carbon fiber knitting machine and the knitting method.

  A skin film 14 through which at least the reinforcing fibers (eyes) of the fiber sheet 12 can be seen through is joined to one surface of the fiber sheet 12, specifically, the surface (outer surface) of the fiber molded product. An acrylic resin film such as highly transparent polymethyl methacrylate (PMMA) or polymethacrylate (PMA) can be used for the skin film 14. The acrylic resin is included in a thermoplastic resin that can be subjected to hot press molding, but a thermosetting resin film may be used depending on the application and function. As will be described later, the skin film 14 has a formability that can be preformed when the fiber laminated sheet member 10 in a state where the skin film 14 is coated on the surface of the fiber sheet 12 is preformed. There is a need. Moreover, in order to improve the designability of the fiber molded product, the skin film 14 is transparent so that the reinforcing fibers (eyes) of the fiber sheet 12 can be seen through. In addition, depending on the use etc. of a fiber molded product, it does not need to be colorless.

  A base film 16 serving as a base material of the sheet member 10 is bonded to the other surface of the fiber sheet 12, specifically, the back surface (inner surface) of the fiber molded product. The base film 16 may be any film as long as it is made of, for example, a thermoplastic resin film and has a moldability that enables preforming of the fiber-laminated sheet member 10 described later. A packing film made of (polyethylene) or PP (polypropylene) can be used. For example, the thinner the base film 16 is, the easier it is to perform preforming, which will be described later. However, in order to maintain the shape after the preforming, the substrate film 16 after the preforming needs to have a prescribed strength. A film thickness that can achieve the specified strength is required. The base film 16 does not have to be transparent, but may be transparent.

  These fiber sheets 12 and films 14 and 16 are pulled out from a state of being wound in a roll shape, for example, inserted into a roll forming machine, and pressed by the roll forming machine to be joined as a fiber laminated sheet member 10. . When the fiber sheet 12 and the films 14 and 16 are continuous bodies, the fiber laminated sheet member 10 is also a continuous body, and may be wound up in, for example, a roll shape. Further, the continuous sheet member 10 may be cut into a predetermined length and stacked as, for example, a rectangular sheet body.

  In addition, since the fiber laminated sheet member 10 of this embodiment can be seen through the fibers of the fiber sheet 12 from the surface, when handling the sheet member 10 by hand at the time of preforming and finished product molding described later, There is no problem in aligning the fibers of the fiber sheet 12 in the direction required for the molded product. On the other hand, in the state of the fiber laminated sheet member 10, a mark that can detect, recognize, and identify the fiber eye of the fiber sheet 12 or the direction of the eye mechanically, optically, and electrically, such as a concave portion or a reflection -By providing a transmission part, a conduction part, etc., it becomes possible to automatically set the sheet member 10 in a subsequent process.

  The fiber laminated sheet member 10 created in this way is cut into, for example, specified dimensions, and is set in a preforming mold 20 shown in FIG. 2 and preformed. In the pre-forming, heating may be performed according to the material of the sheet member 10 and the required pre-formed shape. As described above, when the films 14 and 16 are thermoplastic resins, pre-molding is facilitated by hot pressing with the preforming mold 20. This preforming is performed so that the skin film 14 of the fiber laminated sheet member 10 becomes the surface (outer surface) of the fiber molded product (finished product).

  The preformed product of the resin laminated sheet member 10 thus preformed is set in the molding die 22 shown in FIG. 3, and the back side of the fiber molded product (finished product), that is, the resin laminated sheet member 10 is used. A thermoplastic resin 18 is injection-molded on the base film 16 side. When the thermoplastic resin 18 is cured on the back side of the molded product, a prescribed strength is imparted to the fiber molded product. The thermoplastic resin 18 may contain carbon (reinforced) fibers. That is, in that case, CFRTP is injection-molded on the back side of the preform. As is well known, since CFRTP containing carbon fiber exhibits a high strength after curing, a CFRTP molding layer is formed on the back side of the fiber molded product, so that a much greater strength is imparted to the fiber molded product. Is done. After the thermoplastic resin 18 is cured, it is released from the molded product. The carbon (reinforced) fiber contained in the thermoplastic resin 18 may be discontinuous carbon (reinforced) fiber.

  In a general CFRP, a carbon fiber sheet made of a carbon fiber woven fabric is stacked in several layers and set in a mold, and a thermosetting resin is injected into the mold. The thermosetting resin is impregnated into the carbon fiber sheet and cured to form a fiber molded product. Prior to setting in the mold, the laminated carbon fiber sheets may be preshaped. In some cases, the inside of the mold is decompressed simultaneously with the injection of the thermosetting resin. The carbon fiber itself has high strength, but the strength of the fiber molded product is ensured by stacking several layers of this carbon fiber sheet.

  On the other hand, carbon fiber woven fabrics are poor in flexibility and softness like general fiber woven fabrics. Therefore, when the carbon fiber sheet is folded and set in the mold, the sheet is liable to be wrinkled or wrinkled, particularly at a place where the carbon fiber sheet is folded from two directions, and productivity and productivity are easily reduced. Moreover, since the lamination | stacking and setting of the carbon fiber sheet to a shaping die or a pre-shaped shaping die are generally performed manually, it takes an effort and time. Furthermore, since it takes time to inject and cure the thermosetting resin, the production of the fiber molded product requires labor and time, and the productivity is low. As a result, the molded product becomes expensive.

  On the other hand, in the fiber laminated sheet member 10 of this embodiment and the method for producing a fiber molded article using the fiber laminated sheet member 10, a transparent skin film 14 is formed on one surface of the fiber sheet 12 made of a carbon fiber knitted fabric. And the base film 16 is joined to the other surface to form the fiber laminated sheet member 10, and after the sheet member 10 is preformed, it is set in a molding die 22 and heated on the back side of the fiber molded product. The plastic resin 18 is injection molded. The fiber sheet 12 made of a carbon fiber knitted fabric is rich in flexibility and flexibility, and is easy to mold. For example, the fiber sheet 12 is less likely to wrinkle or wrinkle at the time of preforming, and the strength of the fiber molded product does not decrease. Will not drop.

  Thus, according to this embodiment, the skin film 14 in which the reinforcing fibers can be seen through is joined to one surface of the fiber sheet 12 made of a knitted fabric of reinforcing (carbon) fibers, and the fiber laminated sheet member is joined to the other surface. Since the base film 16 constituting the base portion 10 is joined to obtain the fiber laminated sheet member 10, the fiber sheet 12 made of a knitted reinforced fiber is excellent in flexibility and flexibility and can be easily molded. Even when the member 10 is set in the preforming mold 20 and preforming, it is difficult for wrinkles and wrinkles to occur, so the productivity of the fiber molded product is improved, and the eyes of the reinforcing fibers can be seen through the skin film 14. It is also excellent in design.

  Further, by setting the fiber laminated sheet member 10 in the molding die 22 and injection-molding the thermoplastic resin 18 on the base film 16 side, a prescribed strength can be imparted to the fiber molded product.

  Further, by pre-molding the fiber laminated sheet member 10 in the preforming mold 20 before the injection molding of the thermoplastic resin 18, the fiber molded product can be surely formed into a specified shape.

  Moreover, the strength of the fiber molded product can be further improved by containing the reinforcing fiber in the thermoplastic resin 18.

  Next, a second embodiment of the fiber laminated sheet member of the present invention and a method for producing a fiber molded article using the fiber laminated sheet member will be described. FIG. 4 is an explanatory diagram of a lamination process showing the fiber laminated sheet member of this embodiment. Also in this embodiment, for example, by roll forming, the reinforcing fiber eyes can be seen through one surface of the fiber sheet 12 made of the same carbon fiber knitted fabric as in the first embodiment, as in the first embodiment. In this embodiment, a thermoplastic resin sheet 24 is bonded to the other surface of the fiber sheet 12. The thermoplastic resin of the thermoplastic resin sheet 24 may contain carbon fibers. That is, a CFRTP sheet may be joined. In this embodiment, as will be described later, the fiber laminated sheet member 10 is hot press-molded to produce a fiber molded product, so that the strength of the fiber molded product can be obtained by hot press molding, specifically In this case, a thick thermoplastic resin sheet or CFRTP sheet is used. In addition, the fiber sheet 12 and the skin film 14 can use the thing equivalent to 1st Embodiment mentioned above. Moreover, the mark which can detect the fiber eyes of the fiber sheet 12, or the direction of the eyes can also be provided similarly to 1st Embodiment.

  In this embodiment, the fiber-laminated sheet member 10 obtained in the laminating step of FIG. 4 is hot press-molded in a thermoforming mold 26 to form a molded product as shown in FIG. The fiber laminated sheet member 10 of this embodiment has a laminated structure of a skin film 14, a fiber sheet 12, and a thermoplastic resin sheet 24. In particular, the thermoplastic resin sheet 24 is heat-formed by hot press molding. When the thermoplastic resin sheet 24, and optionally the thermoplastic resin sheet 24 containing carbon fibers, is cured, a prescribed strength is imparted to the fiber molded product. After curing, the fiber molded product is released and taken out. As described above, in this embodiment, in addition to the effects of the first embodiment, there is an effect that a fiber molded product having a prescribed strength can be obtained only by hot press molding the fiber laminated sheet member 10. .

  Thus, according to this embodiment, the skin film 14 through which the reinforcing fibers can be seen through is joined to one surface of the fiber sheet 12 made of a knitted fabric of reinforcing (carbon) fibers, and the thermoplastic resin sheet is joined to the other surface. Since the fiber laminated sheet member 10 is formed by bonding 24, the fiber sheet 12 made of a knitted reinforced fiber is excellent in flexibility and flexibility and is easy to mold. Even when set in a hot press molding, warping and wrinkling are less likely to occur, so that the productivity of the molded product is improved, and the eyes of the fibers can be seen through the skin film 14, so that the design is excellent. Moreover, a strong molded product can be obtained only by hot press-molding the fiber laminated sheet member 10.

  Moreover, the intensity | strength of a fiber molded product can be improved further by containing a reinforced fiber in the thermoplastic resin sheet 24. FIG.

  Further, by setting the fiber laminated sheet member 10 in a thermoforming mold and performing hot press molding, a strong molded product can be obtained only by hot press molding the fiber laminated sheet member 10.

  It goes without saying that the present invention includes various embodiments not described above. Therefore, the technical scope of the present invention is defined only by the invention-specifying matters described in the scope of claims which is appropriate from the above description.

DESCRIPTION OF SYMBOLS 10 Fiber laminated sheet member 12 Fiber sheet 14 Skin film 16 Base film 18 Thermoplastic resin 20 Preliminary mold 22 Mold (mold)
24 Thermoplastic resin sheet 26 Thermoforming mold

Claims (7)

In the fiber laminated sheet member formed by coating both sides of the fiber sheet with a film,
The fiber sheet is composed of a knitted fabric of reinforcing fibers,
Of the films coated on both sides of the fiber sheet, at least one is transparent,
A fiber laminated sheet member, wherein films coated on both sides of the fiber sheet have formability.   When the fiber laminated sheet member according to claim 1 is set in a mold and only one of the films coated on both sides of the fiber sheet is transparent, the fiber laminated sheet member is opposite to the transparent film, or the fiber. A method for producing a fiber molded article using a fiber laminated sheet member, wherein a thermoplastic resin is injection-molded on either film side when both films coated on both sides of the sheet are transparent.   The method for producing a fiber molded article using a fiber laminated sheet member according to claim 2, wherein the fiber laminated sheet member is preformed in a preforming mold before injection molding of the thermoplastic resin. .   The method for producing a fiber molded article using the fiber laminated sheet member according to claim 2, wherein reinforcing fibers are contained in the thermoplastic resin. In the fiber laminated sheet member in which one side of the fiber sheet is covered with a film and the other side is covered with a sheet,
The fiber sheet is composed of a knitted fabric of reinforcing fibers,
The film coated on one surface of the fiber sheet is transparent and has moldability,
The fiber-laminated sheet member, wherein the sheet coated on the other surface of the fiber sheet is a thermoplastic resin sheet.   The fiber-laminated sheet member according to claim 5, wherein reinforcing fibers are contained in the thermoplastic resin sheet.   A method for producing a fiber molded article using a fiber laminated sheet member, wherein the fiber laminated sheet member according to claim 5 or 6 is set in a thermoforming mold and subjected to hot press molding.

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